Thermo-energetic Design of Machine Tools
A Systemic Approach to Solve the Conflict Between Power Efficiency, Accuracy and Productivity Demonstrated at the Example of Machining Production
1st Edition
Published on 6. November 2014
X, 261 pages
978-3-319-12625-8 (ISBN)
Description
The approach to the solution within the CRC/TR 96 financed by the German Research Foundation DFG aims at measures that will allow manufacturing accuracy to be maintained under thermally unstable conditions with increased productivity, without an additional demand for energy for tempering. The challenge of research in the CRC/TR 96 derives from the attempt to satisfy the conflicting goals of reducing energy consumption and increasing accuracy and productivity in machining.
In the current research performed in 19 subprojects within the scope of the CRC/TR 96, correction and compensation solutions that influence the thermo-elastic machine tool behaviour efficiently and are oriented along the thermo-elastic functional chain are explored and implemented. As part of this general objective, the following issues must be researched and engineered in an interdisciplinary setting and brought together into useful overall solutions:
1. Providing the modelling fundamentals to calculate the heat fluxes and the resulting thermo-elastic deformations in a comprehensive manner,
2. Mapping of the structural variability as a result of the relative movement inside the machine tool,
3. Providing the tools for an efficient adjustment of parameters that vary greatly in time and space by means of parameter identification methods as a prerequisite for correction and compensation solutions,
4. Engineering and demonstrating solutions to control-integrated correction of thermo-elastic errors by an inverse position setpoint compensation of the error at theTCP,
5. Engineering and demonstrating solutions based on the material properties to compensate for thermo-elastic effects through a homogeneous propagation of the temperature field, as well as reducing and smoothing the distribution of heat dissipated in supporting structures,
6. Developing metrological fundamentals to record the thermo-elastic errors in special structural areas of machine tools,
7. Engineering a methodological approach to simultaneous and complex evaluation of the CRC/TR 96 solutions, referring to their impact on product quality, production rate, energy consumption and machine tool costs
More details
Series
Language
English
Place of publication
Cham
Switzerland
Publishing group
Springer International Publishing
Target group
Professional and scholarly
Product notice
Reflowable
Illustrations
X, 261 p. 151 illus., 81 illus. in color.
File size
11,39 MB
ISBN-13
978-3-319-12625-8 (9783319126258)
DOI
10.1007/978-3-319-12625-8
Schweitzer Classification
Other editions
Additional editions
Knut Großmann
Thermo-energetic Design of Machine Tools
A Systemic Approach to Solve the Conflict Between Power Efficiency, Accuracy and Productivity Demonstrated at the Example of Machining Production
Book
11/2014
Springer
€106.99
Shipment within 10-15 days
Content
1 - Contents [Seite 6]
2 - Abbreviations [Seite 9]
3 - 1 Introduction [Seite 11]
3.1 - Abstract [Seite 11]
3.2 - 1.1 Problem [Seite 11]
3.3 - 1.2 Objectives and Project Structure of the CRC/TR 96 [Seite 13]
3.4 - 1.3 Design-Integrated Compensation and Control-Integrated Correction [Seite 16]
3.5 - 1.4 Metrological Analysis and Benchmarking [Seite 17]
3.6 - 1.5 Test Beds and Demonstrators [Seite 17]
3.7 - References [Seite 21]
4 - 2 Model-Based Representation of Thermo-energetic Effects in Cutting Tools and Part Clamping Devices [Seite 22]
4.1 - Abstract [Seite 22]
4.2 - 2.1 Introduction [Seite 23]
4.2.1 - 2.1.1 Motivation and Problem Definition [Seite 23]
4.2.2 - 2.1.2 Aim [Seite 23]
4.3 - 2.2 Approach [Seite 24]
4.3.1 - 2.2.1 Test Bed Description [Seite 24]
4.3.2 - 2.2.2 Subject of Experimental Investigations [Seite 24]
4.3.3 - 2.2.3 Simulation Assisted Investigations [Seite 26]
4.4 - 2.3 Results [Seite 27]
4.4.1 - 2.3.1 Temperature Fields and Thermo-elastic Elongation in the Chuck [Seite 27]
4.4.2 - 2.3.2 Simulation Results and Adjustment with Experimental Investigations [Seite 28]
4.4.3 - 2.3.3 Determination of Process Heat Parameters [Seite 30]
4.5 - 2.4 Classification of Outcomes in the SFB/TR 96 [Seite 32]
4.6 - 2.5 Outlook [Seite 33]
4.7 - References [Seite 33]
5 - 3 Model and Method for the Determination and Distribution of Converted Energies in Milling Processes [Seite 35]
5.1 - Abstract [Seite 35]
5.2 - 3.1 Introduction [Seite 35]
5.3 - 3.2 Approach [Seite 36]
5.4 - 3.3 Results [Seite 37]
5.4.1 - 3.3.1 Derivation of Analytical Temperature Models in Metal Cutting [Seite 37]
5.4.2 - 3.3.2 Measurement of Temperature Fields in Metal Cutting [Seite 38]
5.4.3 - 3.3.3 Equation for the Heat Flux [Seite 40]
5.5 - 3.4 Classification of Outcomes CRC/TR 96 [Seite 41]
5.6 - 3.5 Outlook [Seite 42]
5.7 - References [Seite 42]
6 - 4 Energy Model for Grinding Processes [Seite 43]
6.1 - Abstract [Seite 43]
6.2 - 4.1 Introduction [Seite 44]
6.3 - 4.2 Approach [Seite 44]
6.3.1 - 4.2.1 Methodology to Model the Heat Sources in the Grinding Process [Seite 44]
6.3.2 - 4.2.2 Energy Model for Single Grain Engagement [Seite 45]
6.4 - 4.3 Results [Seite 47]
6.4.1 - 4.3.1 Investigations to Characterize Chip Formation [Seite 47]
6.4.2 - 4.3.2 Analysis of Energy Conversion During Chip Formation [Seite 49]
6.4.3 - 4.3.3 Transferring the Energy Model onto the Multi Grain Engagement [Seite 53]
6.5 - 4.4 Classification of Outcomes in the CRC/TR 96 [Seite 54]
6.6 - 4.5 Outlook [Seite 54]
6.7 - References [Seite 55]
7 - 5 Thermo-energetic Modelling of Fluid Power Systems [Seite 56]
7.1 - Abstract [Seite 56]
7.2 - 5.1 Introduction [Seite 56]
7.3 - 5.2 Approach [Seite 57]
7.4 - 5.3 Results [Seite 58]
7.4.1 - 5.3.1 Complete Machine Analysis of a Milling Centre [Seite 58]
7.4.2 - 5.3.2 Experimental Component Analysis of the Motor Spindle Cooling Sleeve [Seite 63]
7.4.3 - 5.3.3 Simulation Model for the Calculation of the Motor Spindle Cooling Sleeve [Seite 64]
7.5 - 5.4 Classification of Outcomes CRC/TR 96 [Seite 65]
7.6 - References [Seite 66]
8 - 6 Simulation of Pose- and Process-Dependent Machine Tool Models [Seite 67]
8.1 - Abstract [Seite 67]
8.2 - 6.1 Introduction [Seite 67]
8.3 - 6.2 Approach to Mapping of Structural Variability [Seite 68]
8.3.1 - 6.2.1 General Strategy to Represent Discrete Motions [Seite 69]
8.3.2 - 6.2.2 Motion in FE Models---Selected Aspects [Seite 70]
8.4 - 6.3 Results [Seite 72]
8.4.1 - 6.3.1 Example of Profile Rail Guidance [Seite 72]
8.5 - 6.4 Classification in the CRC/TR 96 [Seite 73]
8.6 - 6.5 Outlook [Seite 73]
8.7 - References [Seite 74]
9 - 7 Thermo-Elastic Simulation of Entire Machine Tool [Seite 75]
9.1 - Abstract [Seite 75]
9.2 - 7.1 Introduction [Seite 75]
9.3 - 7.2 Approach [Seite 76]
9.4 - 7.3 Results [Seite 77]
9.4.1 - 7.3.1 Model Order Reduction [Seite 77]
9.4.2 - 7.3.2 Structure and Parameter Preserving Krylov Model Order Reduction [Seite 78]
9.4.3 - 7.3.3 Handling of Structural Variability [Seite 80]
9.4.3.1 - 7.3.3.1 Thermal Model [Seite 80]
9.4.3.2 - 7.3.3.2 Mechanical Model [Seite 81]
9.4.3.3 - 7.3.3.3 Thermo-Elastic Model [Seite 82]
9.4.4 - 7.3.4 Practice Implementation of the Approach Shown for a Ball Screw Axis [Seite 83]
9.4.5 - 7.3.5 Calculation Results and Performance [Seite 87]
9.4.5.1 - 7.3.5.1 ANSYS Versus Matlab/Simulink Calculation [Seite 87]
9.4.5.2 - 7.3.5.2 Simulation Versus Experiment: Column-Spindle Head [Seite 87]
9.4.5.3 - 7.3.5.3 Simulation Versus Experiment: Ball Screw Based Strut Axis [Seite 88]
9.5 - 7.4 Classification Among the Objectives of the CRC/TR 96 [Seite 89]
9.6 - 7.5 Outlook [Seite 90]
9.7 - References [Seite 90]
10 - 8 Model Order Reduction for Thermo-Elastic Assembly Group Models [Seite 91]
10.1 - Abstract [Seite 91]
10.2 - 8.1 Introduction [Seite 91]
10.3 - 8.2 MOR for Switched and Coupled Systems [Seite 94]
10.4 - 8.3 PMOR by the Iterative Rational Krylov Algorithm [Seite 96]
10.5 - 8.4 Integration into the CRC/Transregio [Seite 98]
10.6 - References [Seite 99]
11 - 9 High-Accuracy Thermo-Elastic Simulation on Massively Parallel Computer [Seite 100]
11.1 - Abstract [Seite 100]
11.2 - 9.1 Introduction [Seite 100]
11.3 - 9.2 Approaches [Seite 103]
11.3.1 - 9.2.1 Mathematical Model for Heat Exchange [Seite 103]
11.3.2 - 9.2.2 Spatial Discretization for Contact Problem in a Simplified Geometry [Seite 103]
11.3.2.1 - 9.2.2.1 The Diffuse-Domain Method [Seite 103]
11.3.2.2 - 9.2.2.2 Explicit Contact Formulation [Seite 105]
11.3.3 - 9.2.3 Efficient Long-Term Integration of the Column Geometry [Seite 106]
11.3.3.1 - 9.2.3.1 Defect Corrected Averaging [Seite 106]
11.3.3.2 - 9.2.3.2 Preconditioning in Defect Corrected Averaging [Seite 109]
11.4 - 9.3 Results [Seite 110]
11.4.1 - 9.3.1 Comparison of the Diffuse-Domain Method with Explicit Formulation of the Contact [Seite 110]
11.4.2 - 9.3.2 Results of Defect Corrected Averaging [Seite 112]
11.5 - 9.4 Classification in the CRC/TR 96 [Seite 114]
11.6 - 9.5 Outlook [Seite 114]
11.7 - References [Seite 115]
12 - 10 Modelling of Thermal Interactions Between Environment and Machine Tool [Seite 116]
12.1 - Abstract [Seite 116]
12.2 - 10.1 Introduction [Seite 116]
12.3 - 10.2 Approach [Seite 117]
12.4 - 10.3 Results [Seite 118]
12.4.1 - 10.3.1 Modelling of Thermal Influences and Interactions [Seite 118]
12.4.1.1 - 10.3.1.1 Representation of the Boundary Conditions for Convection [Seite 118]
12.4.1.1.1 - Numerical Versus Analytical Calculation [Seite 118]
12.4.1.2 - 10.3.1.2 Representation of the Radiation Boundary Conditions [Seite 121]
12.4.2 - 10.3.2 Sensitivity Analysis on a Machine Tool Structure [Seite 124]
12.4.3 - 10.3.3 Verification in Experiment [Seite 128]
12.5 - 10.4 Classification According to the Goals of the CRC/TR 96 and Outlook [Seite 128]
12.6 - References [Seite 129]
13 - 11 Determination and Modelling of Heat Transfer Mechanisms Acting Among Machine Tool Components [Seite 130]
13.1 - Abstract [Seite 130]
13.2 - 11.1 Introduction [Seite 130]
13.3 - 11.2 Approach [Seite 133]
13.3.1 - 11.2.1 Determination of Contact Heat Transfer in Experiments [Seite 133]
13.3.2 - 11.2.2 Modelling the Contact Heat Transfer [Seite 135]
13.4 - 11.3 Results [Seite 136]
13.5 - 11.4 Classification of Outcomes in the CRC/TR 96 [Seite 137]
13.6 - 11.5 Outlook [Seite 138]
13.7 - References [Seite 138]
14 - 12 Investigation of Components and Assembly Groups [Seite 139]
14.1 - Abstract [Seite 139]
14.2 - 12.1 Introduction [Seite 140]
14.3 - 12.2 Approach [Seite 141]
14.3.1 - 12.2.1 Guidance Systems [Seite 141]
14.3.2 - 12.2.2 Ball Screws [Seite 142]
14.3.3 - 12.2.3 Demonstrator Machine Tool [Seite 143]
14.4 - 12.3 Results [Seite 144]
14.4.1 - 12.3.1 Rail Guidance Systems [Seite 144]
14.4.2 - 12.3.2 Ball Screws [Seite 145]
14.4.3 - 12.3.3 The Machine Tool as a Whole [Seite 146]
14.5 - 12.4 Classification of Outcomes CRC/TR 96 [Seite 147]
14.6 - 12.5 Outlook [Seite 148]
14.7 - References [Seite 148]
15 - 13 Adjustment of Uncertain Parameters in Thermal Models of Machine Tools [Seite 149]
15.1 - Abstract [Seite 149]
15.2 - 13.1 Introduction [Seite 149]
15.2.1 - 13.1.1 Uncertain Parameters in Thermal Models [Seite 150]
15.2.2 - 13.1.2 Adjustment of Uncertain Parameters [Seite 152]
15.3 - 13.2 Approach [Seite 153]
15.3.1 - 13.2.1 Engineering of Efficient Parameter Adjustment Methods [Seite 153]
15.3.2 - 13.2.2 Information Processing Methods for Parameter Adjustment [Seite 155]
15.4 - 13.3 Results [Seite 156]
15.4.1 - 13.3.1 Visualisation for the Parameter Influence Analysis [Seite 156]
15.4.2 - 13.3.2 Load Cases for Data Acquisition [Seite 158]
15.5 - 13.4 Summary and Outlook [Seite 160]
15.6 - References [Seite 160]
16 - 14 Correction Algorithms and High-Dimensional Characteristic Diagrams [Seite 162]
16.1 - Abstract [Seite 162]
16.2 - 14.1 Determination of Relevant Parameters Using Adjoint-Based Sensitivity Analysis [Seite 162]
16.2.1 - 14.1.1 Background of Adjoint-Based Sensitivity Analysis [Seite 163]
16.2.2 - 14.1.2 Numerical Results [Seite 166]
16.3 - 14.2 Optimal Placement of Temperature Sensors for the Estimation of the TCP Displacement [Seite 167]
16.3.1 - 14.2.1 TCP Displacement Estimation [Seite 167]
16.3.2 - 14.2.2 Optimization of the Estimator's Quality [Seite 169]
16.3.3 - 14.2.3 Numerical Results [Seite 171]
16.4 - 14.3 Characteristic Diagrams [Seite 172]
16.5 - 14.4 Integration into the CRC/TR 96 and Outlook [Seite 176]
16.6 - References [Seite 177]
17 - 15 Correction Model of Load-Dependent Structural Deformations Based on Transfer Functions [Seite 178]
17.1 - Abstract [Seite 178]
17.2 - 15.1 Introduction [Seite 178]
17.3 - 15.2 Approach [Seite 179]
17.3.1 - 15.2.1 Correction Method [Seite 179]
17.3.2 - 15.2.2 Experimental Methodology [Seite 181]
17.4 - 15.3 Results [Seite 181]
17.4.1 - 15.3.1 Stressing Unit for a Targeted Load of the Machine Axes [Seite 182]
17.4.2 - 15.3.2 Displacement Model for One Point in the Workspace [Seite 182]
17.4.3 - 15.3.3 Development of a Volumetric Method to Measure Thermo-Elastic Displacements [Seite 184]
17.5 - 15.4 Classification of Outcomes CRC/TR 96 [Seite 185]
17.6 - 15.5 Outlook [Seite 185]
17.7 - References [Seite 186]
18 - 16 Structural Model-Based Correction of Thermo-elastic Machine Tool Errors [Seite 187]
18.1 - Abstract [Seite 187]
18.2 - 16.1 Introduction [Seite 187]
18.3 - 16.2 Approach [Seite 188]
18.4 - 16.3 Results [Seite 190]
18.4.1 - 16.3.1 Real Time Thermal Model [Seite 190]
18.4.2 - 16.3.2 Requirements in Terms of the Load Data's Sampling Intervals [Seite 191]
18.4.3 - 16.3.3 Local Assignment [Seite 192]
18.4.4 - 16.3.4 Position-Dependent Calculation of the Correction Value [Seite 194]
18.4.5 - 16.3.5 Implementation of Load Data Capture in the TwinCAT3 Control [Seite 195]
18.4.6 - 16.3.6 Test of Control-Integrated Load Data Capture and Temperature Field Calculation [Seite 196]
18.5 - 16.4 Classification of Outcomes in the CRC/TR 96 [Seite 197]
18.5.1 - 16.4.1 Applicability Options for Structural Model-Based Correction [Seite 197]
18.6 - 16.5 Outlook [Seite 198]
18.7 - References [Seite 198]
19 - 17 Modelling and Design of Systems for Active Control of Temperature Distribution in Frame Subassemblies [Seite 200]
19.1 - Abstract [Seite 200]
19.2 - 17.1 Introduction [Seite 200]
19.3 - 17.2 Approach [Seite 201]
19.4 - 17.3 Results [Seite 202]
19.4.1 - 17.3.1 Material Composite of Phase-Change Material and Metal Foam [Seite 202]
19.4.2 - 17.3.2 Switchable Thermal Conduction Based on Shape Memory Alloys [Seite 204]
19.4.3 - 17.3.3 Switchable Thermal Conduction Based on Magnetorheological Fluids [Seite 206]
19.5 - 17.4 Classification in the CRC/TR 96 [Seite 208]
19.6 - 17.5 Outlook [Seite 208]
19.7 - References [Seite 208]
20 - 18 Structurally Integrated Sensors [Seite 210]
20.1 - Abstract [Seite 210]
20.2 - 18.1 Introduction [Seite 210]
20.3 - 18.2 Configuration of Sensor Applications [Seite 211]
20.3.1 - 18.2.1 Measurement Principle [Seite 211]
20.3.2 - 18.2.2 Sensor Arrangement in Complex Machine Structures [Seite 212]
20.4 - 18.3 Test Bed Results [Seite 213]
20.4.1 - 18.3.1 Determining the Suitability of the Sensor Applications [Seite 213]
20.4.1.1 - 18.3.1.1 Verification of the Measurement Principle [Seite 214]
20.4.1.1.1 - Tests Designed to Determine the Suitability of the Sensor Application [Seite 214]
20.4.1.2 - 18.3.1.2 Long-Term Stability Tests [Seite 216]
20.4.2 - 18.3.2 Validation Measurements [Seite 218]
20.5 - 18.4 Classification in the CRC [Seite 221]
20.6 - 18.5 Outlook [Seite 221]
20.7 - References [Seite 221]
21 - 19 Thermo-Energetic Motor Optimisation [Seite 223]
21.1 - Abstract [Seite 223]
21.2 - 19.1 Introduction [Seite 223]
21.3 - 19.2 Approach [Seite 224]
21.4 - 19.3 Results [Seite 224]
21.4.1 - 19.3.1 Power Dissipation Models [Seite 224]
21.4.2 - 19.3.2 Thermal Models [Seite 229]
21.5 - 19.4 Classification in the CRC/TR 96 [Seite 230]
21.6 - 19.5 Outlook [Seite 230]
21.7 - References [Seite 231]
22 - 20 Technical and Economic Benchmarking Guideline for the Compensation and Correction of Thermally Induced Machine Tool Errors [Seite 232]
22.1 - Abstract [Seite 232]
22.2 - 20.1 Introduction [Seite 232]
22.3 - 20.2 The Benchmarking Model [Seite 234]
22.3.1 - 20.2.1 Partial Model ``Machine Tool Configuration'' [Seite 235]
22.3.2 - 20.2.2 Application Conditions [Seite 236]
22.3.3 - 20.2.3 Benchmarking Criteria [Seite 238]
22.3.3.1 - 20.2.3.1 Benchmarking Criteria for Benefit Description [Seite 238]
22.3.3.1.1 - Machining Accuracy [Seite 238]
22.3.3.1.2 - Process Quality (Variance) [Seite 239]
22.3.3.1.3 - Productivity [Seite 240]
22.3.3.1.4 - Energy Consumption [Seite 240]
22.3.3.2 - 20.2.3.2 Benchmarking Criteria Representing Costs [Seite 240]
22.3.3.2.1 - Machine Life Cycle Costs [Seite 241]
22.3.3.2.2 - Engineering Workflows [Seite 242]
22.4 - 20.3 Model Application [Seite 243]
22.5 - 20.4 Classification in the CRC/TR 96 and Outlook [Seite 243]
22.6 - References [Seite 244]
23 - 21 Experimental Analysis of the Thermo-Elastic Behaviour of Machine Tools by Means of Selective Thermography and Close-Range Photogrammetry [Seite 246]
23.1 - Abstract [Seite 246]
23.2 - 21.1 Introduction [Seite 246]
23.3 - 21.2 Approach [Seite 248]
23.3.1 - 21.2.1 Measuring Method of Selective Thermography [Seite 248]
23.4 - 21.3 Results [Seite 250]
23.4.1 - 21.3.1 Preliminary Investigations and Photogrammetric Deformation and Position Measurements at the Test Bed [Seite 250]
23.4.2 - 21.3.2 Development of Software to Execute and Analyse Photogrammetric and Selective Thermographic Measurements [Seite 252]
23.4.3 - 21.3.3 Characterisation of Targets and Design of a Procedure to Calibrate a Camera Fixture [Seite 252]
23.4.4 - 21.3.4 Selective Thermographic Temperature Measurement of a Machine Column [Seite 253]
23.4.5 - 21.3.5 Photogrammetric Measurement of Thermally Affected Displacements on a Hexapod [Seite 256]
23.5 - 21.4 Classification of Outcomes in the CRC/TR 96 [Seite 258]
23.6 - 21.5 Outlook [Seite 259]
23.7 - References [Seite 259]
2 - Abbreviations [Seite 9]
3 - 1 Introduction [Seite 11]
3.1 - Abstract [Seite 11]
3.2 - 1.1 Problem [Seite 11]
3.3 - 1.2 Objectives and Project Structure of the CRC/TR 96 [Seite 13]
3.4 - 1.3 Design-Integrated Compensation and Control-Integrated Correction [Seite 16]
3.5 - 1.4 Metrological Analysis and Benchmarking [Seite 17]
3.6 - 1.5 Test Beds and Demonstrators [Seite 17]
3.7 - References [Seite 21]
4 - 2 Model-Based Representation of Thermo-energetic Effects in Cutting Tools and Part Clamping Devices [Seite 22]
4.1 - Abstract [Seite 22]
4.2 - 2.1 Introduction [Seite 23]
4.2.1 - 2.1.1 Motivation and Problem Definition [Seite 23]
4.2.2 - 2.1.2 Aim [Seite 23]
4.3 - 2.2 Approach [Seite 24]
4.3.1 - 2.2.1 Test Bed Description [Seite 24]
4.3.2 - 2.2.2 Subject of Experimental Investigations [Seite 24]
4.3.3 - 2.2.3 Simulation Assisted Investigations [Seite 26]
4.4 - 2.3 Results [Seite 27]
4.4.1 - 2.3.1 Temperature Fields and Thermo-elastic Elongation in the Chuck [Seite 27]
4.4.2 - 2.3.2 Simulation Results and Adjustment with Experimental Investigations [Seite 28]
4.4.3 - 2.3.3 Determination of Process Heat Parameters [Seite 30]
4.5 - 2.4 Classification of Outcomes in the SFB/TR 96 [Seite 32]
4.6 - 2.5 Outlook [Seite 33]
4.7 - References [Seite 33]
5 - 3 Model and Method for the Determination and Distribution of Converted Energies in Milling Processes [Seite 35]
5.1 - Abstract [Seite 35]
5.2 - 3.1 Introduction [Seite 35]
5.3 - 3.2 Approach [Seite 36]
5.4 - 3.3 Results [Seite 37]
5.4.1 - 3.3.1 Derivation of Analytical Temperature Models in Metal Cutting [Seite 37]
5.4.2 - 3.3.2 Measurement of Temperature Fields in Metal Cutting [Seite 38]
5.4.3 - 3.3.3 Equation for the Heat Flux [Seite 40]
5.5 - 3.4 Classification of Outcomes CRC/TR 96 [Seite 41]
5.6 - 3.5 Outlook [Seite 42]
5.7 - References [Seite 42]
6 - 4 Energy Model for Grinding Processes [Seite 43]
6.1 - Abstract [Seite 43]
6.2 - 4.1 Introduction [Seite 44]
6.3 - 4.2 Approach [Seite 44]
6.3.1 - 4.2.1 Methodology to Model the Heat Sources in the Grinding Process [Seite 44]
6.3.2 - 4.2.2 Energy Model for Single Grain Engagement [Seite 45]
6.4 - 4.3 Results [Seite 47]
6.4.1 - 4.3.1 Investigations to Characterize Chip Formation [Seite 47]
6.4.2 - 4.3.2 Analysis of Energy Conversion During Chip Formation [Seite 49]
6.4.3 - 4.3.3 Transferring the Energy Model onto the Multi Grain Engagement [Seite 53]
6.5 - 4.4 Classification of Outcomes in the CRC/TR 96 [Seite 54]
6.6 - 4.5 Outlook [Seite 54]
6.7 - References [Seite 55]
7 - 5 Thermo-energetic Modelling of Fluid Power Systems [Seite 56]
7.1 - Abstract [Seite 56]
7.2 - 5.1 Introduction [Seite 56]
7.3 - 5.2 Approach [Seite 57]
7.4 - 5.3 Results [Seite 58]
7.4.1 - 5.3.1 Complete Machine Analysis of a Milling Centre [Seite 58]
7.4.2 - 5.3.2 Experimental Component Analysis of the Motor Spindle Cooling Sleeve [Seite 63]
7.4.3 - 5.3.3 Simulation Model for the Calculation of the Motor Spindle Cooling Sleeve [Seite 64]
7.5 - 5.4 Classification of Outcomes CRC/TR 96 [Seite 65]
7.6 - References [Seite 66]
8 - 6 Simulation of Pose- and Process-Dependent Machine Tool Models [Seite 67]
8.1 - Abstract [Seite 67]
8.2 - 6.1 Introduction [Seite 67]
8.3 - 6.2 Approach to Mapping of Structural Variability [Seite 68]
8.3.1 - 6.2.1 General Strategy to Represent Discrete Motions [Seite 69]
8.3.2 - 6.2.2 Motion in FE Models---Selected Aspects [Seite 70]
8.4 - 6.3 Results [Seite 72]
8.4.1 - 6.3.1 Example of Profile Rail Guidance [Seite 72]
8.5 - 6.4 Classification in the CRC/TR 96 [Seite 73]
8.6 - 6.5 Outlook [Seite 73]
8.7 - References [Seite 74]
9 - 7 Thermo-Elastic Simulation of Entire Machine Tool [Seite 75]
9.1 - Abstract [Seite 75]
9.2 - 7.1 Introduction [Seite 75]
9.3 - 7.2 Approach [Seite 76]
9.4 - 7.3 Results [Seite 77]
9.4.1 - 7.3.1 Model Order Reduction [Seite 77]
9.4.2 - 7.3.2 Structure and Parameter Preserving Krylov Model Order Reduction [Seite 78]
9.4.3 - 7.3.3 Handling of Structural Variability [Seite 80]
9.4.3.1 - 7.3.3.1 Thermal Model [Seite 80]
9.4.3.2 - 7.3.3.2 Mechanical Model [Seite 81]
9.4.3.3 - 7.3.3.3 Thermo-Elastic Model [Seite 82]
9.4.4 - 7.3.4 Practice Implementation of the Approach Shown for a Ball Screw Axis [Seite 83]
9.4.5 - 7.3.5 Calculation Results and Performance [Seite 87]
9.4.5.1 - 7.3.5.1 ANSYS Versus Matlab/Simulink Calculation [Seite 87]
9.4.5.2 - 7.3.5.2 Simulation Versus Experiment: Column-Spindle Head [Seite 87]
9.4.5.3 - 7.3.5.3 Simulation Versus Experiment: Ball Screw Based Strut Axis [Seite 88]
9.5 - 7.4 Classification Among the Objectives of the CRC/TR 96 [Seite 89]
9.6 - 7.5 Outlook [Seite 90]
9.7 - References [Seite 90]
10 - 8 Model Order Reduction for Thermo-Elastic Assembly Group Models [Seite 91]
10.1 - Abstract [Seite 91]
10.2 - 8.1 Introduction [Seite 91]
10.3 - 8.2 MOR for Switched and Coupled Systems [Seite 94]
10.4 - 8.3 PMOR by the Iterative Rational Krylov Algorithm [Seite 96]
10.5 - 8.4 Integration into the CRC/Transregio [Seite 98]
10.6 - References [Seite 99]
11 - 9 High-Accuracy Thermo-Elastic Simulation on Massively Parallel Computer [Seite 100]
11.1 - Abstract [Seite 100]
11.2 - 9.1 Introduction [Seite 100]
11.3 - 9.2 Approaches [Seite 103]
11.3.1 - 9.2.1 Mathematical Model for Heat Exchange [Seite 103]
11.3.2 - 9.2.2 Spatial Discretization for Contact Problem in a Simplified Geometry [Seite 103]
11.3.2.1 - 9.2.2.1 The Diffuse-Domain Method [Seite 103]
11.3.2.2 - 9.2.2.2 Explicit Contact Formulation [Seite 105]
11.3.3 - 9.2.3 Efficient Long-Term Integration of the Column Geometry [Seite 106]
11.3.3.1 - 9.2.3.1 Defect Corrected Averaging [Seite 106]
11.3.3.2 - 9.2.3.2 Preconditioning in Defect Corrected Averaging [Seite 109]
11.4 - 9.3 Results [Seite 110]
11.4.1 - 9.3.1 Comparison of the Diffuse-Domain Method with Explicit Formulation of the Contact [Seite 110]
11.4.2 - 9.3.2 Results of Defect Corrected Averaging [Seite 112]
11.5 - 9.4 Classification in the CRC/TR 96 [Seite 114]
11.6 - 9.5 Outlook [Seite 114]
11.7 - References [Seite 115]
12 - 10 Modelling of Thermal Interactions Between Environment and Machine Tool [Seite 116]
12.1 - Abstract [Seite 116]
12.2 - 10.1 Introduction [Seite 116]
12.3 - 10.2 Approach [Seite 117]
12.4 - 10.3 Results [Seite 118]
12.4.1 - 10.3.1 Modelling of Thermal Influences and Interactions [Seite 118]
12.4.1.1 - 10.3.1.1 Representation of the Boundary Conditions for Convection [Seite 118]
12.4.1.1.1 - Numerical Versus Analytical Calculation [Seite 118]
12.4.1.2 - 10.3.1.2 Representation of the Radiation Boundary Conditions [Seite 121]
12.4.2 - 10.3.2 Sensitivity Analysis on a Machine Tool Structure [Seite 124]
12.4.3 - 10.3.3 Verification in Experiment [Seite 128]
12.5 - 10.4 Classification According to the Goals of the CRC/TR 96 and Outlook [Seite 128]
12.6 - References [Seite 129]
13 - 11 Determination and Modelling of Heat Transfer Mechanisms Acting Among Machine Tool Components [Seite 130]
13.1 - Abstract [Seite 130]
13.2 - 11.1 Introduction [Seite 130]
13.3 - 11.2 Approach [Seite 133]
13.3.1 - 11.2.1 Determination of Contact Heat Transfer in Experiments [Seite 133]
13.3.2 - 11.2.2 Modelling the Contact Heat Transfer [Seite 135]
13.4 - 11.3 Results [Seite 136]
13.5 - 11.4 Classification of Outcomes in the CRC/TR 96 [Seite 137]
13.6 - 11.5 Outlook [Seite 138]
13.7 - References [Seite 138]
14 - 12 Investigation of Components and Assembly Groups [Seite 139]
14.1 - Abstract [Seite 139]
14.2 - 12.1 Introduction [Seite 140]
14.3 - 12.2 Approach [Seite 141]
14.3.1 - 12.2.1 Guidance Systems [Seite 141]
14.3.2 - 12.2.2 Ball Screws [Seite 142]
14.3.3 - 12.2.3 Demonstrator Machine Tool [Seite 143]
14.4 - 12.3 Results [Seite 144]
14.4.1 - 12.3.1 Rail Guidance Systems [Seite 144]
14.4.2 - 12.3.2 Ball Screws [Seite 145]
14.4.3 - 12.3.3 The Machine Tool as a Whole [Seite 146]
14.5 - 12.4 Classification of Outcomes CRC/TR 96 [Seite 147]
14.6 - 12.5 Outlook [Seite 148]
14.7 - References [Seite 148]
15 - 13 Adjustment of Uncertain Parameters in Thermal Models of Machine Tools [Seite 149]
15.1 - Abstract [Seite 149]
15.2 - 13.1 Introduction [Seite 149]
15.2.1 - 13.1.1 Uncertain Parameters in Thermal Models [Seite 150]
15.2.2 - 13.1.2 Adjustment of Uncertain Parameters [Seite 152]
15.3 - 13.2 Approach [Seite 153]
15.3.1 - 13.2.1 Engineering of Efficient Parameter Adjustment Methods [Seite 153]
15.3.2 - 13.2.2 Information Processing Methods for Parameter Adjustment [Seite 155]
15.4 - 13.3 Results [Seite 156]
15.4.1 - 13.3.1 Visualisation for the Parameter Influence Analysis [Seite 156]
15.4.2 - 13.3.2 Load Cases for Data Acquisition [Seite 158]
15.5 - 13.4 Summary and Outlook [Seite 160]
15.6 - References [Seite 160]
16 - 14 Correction Algorithms and High-Dimensional Characteristic Diagrams [Seite 162]
16.1 - Abstract [Seite 162]
16.2 - 14.1 Determination of Relevant Parameters Using Adjoint-Based Sensitivity Analysis [Seite 162]
16.2.1 - 14.1.1 Background of Adjoint-Based Sensitivity Analysis [Seite 163]
16.2.2 - 14.1.2 Numerical Results [Seite 166]
16.3 - 14.2 Optimal Placement of Temperature Sensors for the Estimation of the TCP Displacement [Seite 167]
16.3.1 - 14.2.1 TCP Displacement Estimation [Seite 167]
16.3.2 - 14.2.2 Optimization of the Estimator's Quality [Seite 169]
16.3.3 - 14.2.3 Numerical Results [Seite 171]
16.4 - 14.3 Characteristic Diagrams [Seite 172]
16.5 - 14.4 Integration into the CRC/TR 96 and Outlook [Seite 176]
16.6 - References [Seite 177]
17 - 15 Correction Model of Load-Dependent Structural Deformations Based on Transfer Functions [Seite 178]
17.1 - Abstract [Seite 178]
17.2 - 15.1 Introduction [Seite 178]
17.3 - 15.2 Approach [Seite 179]
17.3.1 - 15.2.1 Correction Method [Seite 179]
17.3.2 - 15.2.2 Experimental Methodology [Seite 181]
17.4 - 15.3 Results [Seite 181]
17.4.1 - 15.3.1 Stressing Unit for a Targeted Load of the Machine Axes [Seite 182]
17.4.2 - 15.3.2 Displacement Model for One Point in the Workspace [Seite 182]
17.4.3 - 15.3.3 Development of a Volumetric Method to Measure Thermo-Elastic Displacements [Seite 184]
17.5 - 15.4 Classification of Outcomes CRC/TR 96 [Seite 185]
17.6 - 15.5 Outlook [Seite 185]
17.7 - References [Seite 186]
18 - 16 Structural Model-Based Correction of Thermo-elastic Machine Tool Errors [Seite 187]
18.1 - Abstract [Seite 187]
18.2 - 16.1 Introduction [Seite 187]
18.3 - 16.2 Approach [Seite 188]
18.4 - 16.3 Results [Seite 190]
18.4.1 - 16.3.1 Real Time Thermal Model [Seite 190]
18.4.2 - 16.3.2 Requirements in Terms of the Load Data's Sampling Intervals [Seite 191]
18.4.3 - 16.3.3 Local Assignment [Seite 192]
18.4.4 - 16.3.4 Position-Dependent Calculation of the Correction Value [Seite 194]
18.4.5 - 16.3.5 Implementation of Load Data Capture in the TwinCAT3 Control [Seite 195]
18.4.6 - 16.3.6 Test of Control-Integrated Load Data Capture and Temperature Field Calculation [Seite 196]
18.5 - 16.4 Classification of Outcomes in the CRC/TR 96 [Seite 197]
18.5.1 - 16.4.1 Applicability Options for Structural Model-Based Correction [Seite 197]
18.6 - 16.5 Outlook [Seite 198]
18.7 - References [Seite 198]
19 - 17 Modelling and Design of Systems for Active Control of Temperature Distribution in Frame Subassemblies [Seite 200]
19.1 - Abstract [Seite 200]
19.2 - 17.1 Introduction [Seite 200]
19.3 - 17.2 Approach [Seite 201]
19.4 - 17.3 Results [Seite 202]
19.4.1 - 17.3.1 Material Composite of Phase-Change Material and Metal Foam [Seite 202]
19.4.2 - 17.3.2 Switchable Thermal Conduction Based on Shape Memory Alloys [Seite 204]
19.4.3 - 17.3.3 Switchable Thermal Conduction Based on Magnetorheological Fluids [Seite 206]
19.5 - 17.4 Classification in the CRC/TR 96 [Seite 208]
19.6 - 17.5 Outlook [Seite 208]
19.7 - References [Seite 208]
20 - 18 Structurally Integrated Sensors [Seite 210]
20.1 - Abstract [Seite 210]
20.2 - 18.1 Introduction [Seite 210]
20.3 - 18.2 Configuration of Sensor Applications [Seite 211]
20.3.1 - 18.2.1 Measurement Principle [Seite 211]
20.3.2 - 18.2.2 Sensor Arrangement in Complex Machine Structures [Seite 212]
20.4 - 18.3 Test Bed Results [Seite 213]
20.4.1 - 18.3.1 Determining the Suitability of the Sensor Applications [Seite 213]
20.4.1.1 - 18.3.1.1 Verification of the Measurement Principle [Seite 214]
20.4.1.1.1 - Tests Designed to Determine the Suitability of the Sensor Application [Seite 214]
20.4.1.2 - 18.3.1.2 Long-Term Stability Tests [Seite 216]
20.4.2 - 18.3.2 Validation Measurements [Seite 218]
20.5 - 18.4 Classification in the CRC [Seite 221]
20.6 - 18.5 Outlook [Seite 221]
20.7 - References [Seite 221]
21 - 19 Thermo-Energetic Motor Optimisation [Seite 223]
21.1 - Abstract [Seite 223]
21.2 - 19.1 Introduction [Seite 223]
21.3 - 19.2 Approach [Seite 224]
21.4 - 19.3 Results [Seite 224]
21.4.1 - 19.3.1 Power Dissipation Models [Seite 224]
21.4.2 - 19.3.2 Thermal Models [Seite 229]
21.5 - 19.4 Classification in the CRC/TR 96 [Seite 230]
21.6 - 19.5 Outlook [Seite 230]
21.7 - References [Seite 231]
22 - 20 Technical and Economic Benchmarking Guideline for the Compensation and Correction of Thermally Induced Machine Tool Errors [Seite 232]
22.1 - Abstract [Seite 232]
22.2 - 20.1 Introduction [Seite 232]
22.3 - 20.2 The Benchmarking Model [Seite 234]
22.3.1 - 20.2.1 Partial Model ``Machine Tool Configuration'' [Seite 235]
22.3.2 - 20.2.2 Application Conditions [Seite 236]
22.3.3 - 20.2.3 Benchmarking Criteria [Seite 238]
22.3.3.1 - 20.2.3.1 Benchmarking Criteria for Benefit Description [Seite 238]
22.3.3.1.1 - Machining Accuracy [Seite 238]
22.3.3.1.2 - Process Quality (Variance) [Seite 239]
22.3.3.1.3 - Productivity [Seite 240]
22.3.3.1.4 - Energy Consumption [Seite 240]
22.3.3.2 - 20.2.3.2 Benchmarking Criteria Representing Costs [Seite 240]
22.3.3.2.1 - Machine Life Cycle Costs [Seite 241]
22.3.3.2.2 - Engineering Workflows [Seite 242]
22.4 - 20.3 Model Application [Seite 243]
22.5 - 20.4 Classification in the CRC/TR 96 and Outlook [Seite 243]
22.6 - References [Seite 244]
23 - 21 Experimental Analysis of the Thermo-Elastic Behaviour of Machine Tools by Means of Selective Thermography and Close-Range Photogrammetry [Seite 246]
23.1 - Abstract [Seite 246]
23.2 - 21.1 Introduction [Seite 246]
23.3 - 21.2 Approach [Seite 248]
23.3.1 - 21.2.1 Measuring Method of Selective Thermography [Seite 248]
23.4 - 21.3 Results [Seite 250]
23.4.1 - 21.3.1 Preliminary Investigations and Photogrammetric Deformation and Position Measurements at the Test Bed [Seite 250]
23.4.2 - 21.3.2 Development of Software to Execute and Analyse Photogrammetric and Selective Thermographic Measurements [Seite 252]
23.4.3 - 21.3.3 Characterisation of Targets and Design of a Procedure to Calibrate a Camera Fixture [Seite 252]
23.4.4 - 21.3.4 Selective Thermographic Temperature Measurement of a Machine Column [Seite 253]
23.4.5 - 21.3.5 Photogrammetric Measurement of Thermally Affected Displacements on a Hexapod [Seite 256]
23.5 - 21.4 Classification of Outcomes in the CRC/TR 96 [Seite 258]
23.6 - 21.5 Outlook [Seite 259]
23.7 - References [Seite 259]
